Daheriya Ritu, Singh V V; International Journal of Advance Research, Ideas and Innovations in Technology

ISSN: 2454-132X
Impact factor: 4.295
(Volume 4, Issue 2)
Available online at: www.ijariit.com

An experimental investigation of the use of industrial waste and

sewage sludge for the production of bricks
Ritu Daheriya V V Singh
ritu0daheriya@gmail.com khatri.rajesh0@gmail.com
NRI Institute of Research and Technology, Bhopal, NRI Institute of Research and Technology, Bhopal,
Madhya Pradesh Madhya Pradesh
ABSTRACT
In many countries, sludge is a serious problem due to its high treatment costs and the risks to the environment and human
health. The sludge presents an increasingly difficult problem to cities of all sizes because of the scarcity of suitable disposal sites,
increasing labor costs, and environmental concerns. The study investigated the use of sludge incorporated with clay. In this
study, bricks were produced with sewage sludge additions ranging from 10, 20, 30, 40 and 50 % by dry weight respectively and
compare produce brick with regular brick. After the testing of all the brick samples for the compressive strength it comes to know
that bricks made up of sludge up to 10 percent can be used for the construction of all the structures as it has the satisfactory
results in the form of the hardness. Also from this investigation, we can solve disposal problem completely and also construct
and economical structure with easy designing.

Keywords: Bricks, Sludge, Waste management, Strength.

1. INTRODUCTION
As we know the human life is totally dependent upon the natural resources available on the earth, so it is our prime duty to save the
natural resources. We can save the Natural resources by recycling, reuse the waste materials. By using waste material after recycling
we can save the natural resources. Waste material includes plastics, glasses, construction material, sewage sludge, Fly Ash etc. Most
of all the waste products are getting recycled using latest techniques, But Dry sludge is the material which is being used only for the
Fertilizer system as manure with any treatment. Dry sludge without any treatment causes soil pollution which can be hazardous to
the human health. Otherwise, the Sludge is dumped into the land, which is also a major issue for the environment. Sludge is produced
on site by treating the wastewater using a septic tank and Off-site by using Activated sludge system. The primary aim of wastewater
treatment is to remove the solid particles present in it. As wastewater contains the organic materials also, which later on converted
into the bacterial cells. These solid waste and bacterial cells can be removed by the treatment of wastewater.

In the earlier days, 6000 B.C. bricks were prepared by an ancient method, in which the moist clay was pressed into the rectangular
moulds by hand and then let it dry in sun light. To prevent the moist clay from the sticking to the moulds, the moulds were dipped
into the water before being filled. After this method, the civilians found that the fired bricks are more favorable as compare to the
sun-dried bricks. The fired clay bricks are more durable and weathering resistant. These fired clay bricks were made under the
wooden fire which maintained for some days. In nowadays, the bricks are made with the partial or fully replacement of clay soil
with the various waste materials like rice husks, sludge, marble dust, tea wastes etc. This paper presents use of dry sludge in the
manufacturing of bricks as a raw material or as the partial replacement of the clay soil in the bricks. There are number of experiments
have been carried away in many countries for the use of sludge in the bricks.

2. PROBLEM STATEMENT
Keeping in view the huge amount of these waste materials, their disposal problems their use in the production of brick appears a
good alternative. Use of these waste materials as replacement of clay for brick production, the present work was undertaken with
following objectives:
 To develop a process of brick production using sludge along with fly ash.

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 Daheriya Ritu, Singh V V; International Journal of Advance Research, Ideas and Innovations in Technology
 Brick production with different proportion of material and compare its properties with conventional bricks.
 To study the effect of dry sludge on brick properties.
 Techno-economic comparison of the designed brick with traditional brick.

3. MIX DESIGN
There are six different series of mixing ratios were tried. However, the batching proportions of raw materials required to produce
brick with nominal dimensions of 20 x 10 x 10 centimeters are shown in below table.
Table 1: Mix Design for Bricks (in %)

% of Sludge Soil Sand (Murrum) Fly Ash Water

0% 71 29 0
10 % 52 26 12
20 % 45 23 12
As per requirements
30 % 38 20 12

40 % 31 17 12

50 % 24 14 12

4. MAKING OF BRICK
In this work, raw materials namely sludge, Fly Ash, and clay are as the major ingredients. They are mix with each other in proportion
as mention in table 4.7 to produce brick. The following steps are taken for making brick.
 First of all raw material with required proportion i.e. sludge and clay are mix together and added water to a sprinkle. And
the mixing of material properly it is kept in the same manner for 12 to 16 hours.
 After 12 to 16 hours the mixture is again mixed properly by adding some water. The all the mixing is done manually with
hand and feet.
 After mixing the lump of the mix is taken, rolled in sand and slapped into mould. The mould used for this study is metal
mould and this mould is empty at drying area where brick is arranged for dry in sunlight.
 When brick is kept in sunlight after every two days they are turned over to facilitate uniform drying and prevent from
warping.
 After 8 to 10 days they are ready to be burnt in kiln. The green bricks arranged in kiln and insulation is provided with a
mud pack. Fire holes are left to ignite the kiln are later sealed to keep the heat inside.
 This is maintained for a week. After a week kiln is disassembled and brick are sorted according to color. Colour is an
indication of the level of burning.

Fig. 1: Making of brick

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 Daheriya Ritu, Singh V V; International Journal of Advance Research, Ideas and Innovations in Technology

Fig. 2: Brick ready for testing

5. TEST CONDUCTED ON BRICKS

5.1 COMPRESSIBILITY TEST (AS PER IS-3495(PART-1):1992
To determine the compressive strength of bricks the compressive strength of bricks are obtained by placing the brick on the flat
horizontal surface between the plates of the testing machine. The axial load is applied at a uniform rate until the brick gets a failure.
The compressive strength of the brick is obtained by using the formula,
Compressive strength=Maximum load at failure/ average area of the surface.

Fig. 3: Compressibility Test

5.2 WATER ABSORPTION TEST (AS PER IS-3495(PART-2):1992

Dry the brick in an oven at a temperature of 105-115°C, cool the brick to the room temperature and it is weighed (M1). Then
immersed the dry brick in water completely at room temperature for 24hrs and remove the brick from the water and wipe out the
traces of water with a cloth and the brick is weighed (M2).
Water absorption= (M2-M1)/ (M1) X100
Where M1 = Dry weight of Sample
M2 = Weight after 24 hrs in water

Fig. 4: Water Absorption test

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 Daheriya Ritu, Singh V V; International Journal of Advance Research, Ideas and Innovations in Technology
5.3 EFFLORESCENCE TEST
The efflorescence test of the brick is conducted by placing the end of the brick in the dish and the distilled water is filled up to the
depth of 25mm.The whole arrangement is made at the room temperature with the well-ventilated room until all water in the dish is
absorbed by the brick and the surface water evaporate. The dish is covered in order to reduce excess evaporation. When the water
is absorbed the bricks appeared to be dry, place a similar quantity in the dish allows it to evaporate as made before.

Fig. 5: Efflorescence Test

The efflorescence is obtained after second evaporation is made.

Nil- No observable deposit of efflorescence
Slight-Less than 10 % area of bricks covered a thin deposit of salt.
Moderate-Covering up to 50% area of the brick
Heavy-Covering 50% or more area of the brick

5.4 SOUNDNESS TEST

The two bricks are taken and made struck with each other. Brick of good quality should not break and produce a ringing sound.

5.5 HARDNESS TEST

Scratch is made on the brick surface with the help of finger nail. If no impression on the surface, the brick is sufficiently hard.

5.6 DIMENSIONS TOLERANCE TEST

The test is performed to check whether the bricks are of required dimensions or not. It is completed in the following manner:

Fig. 6: Dimensions tolerance test

6. RESULTS AND DISCUSSIONS
6.1 COMPRESSIBILITY TEST RESULT
The results of the compressive strength test on the brick made from both fly ash and sludge ash mixtures with three trials are shown
in fig.5.1 and table 5.1.
Table 2: Compressive strength of bricks

% of Sludge Avg. compressive strength, N/mm2

0% 3.82

10 % 3.58

20 % 3.39

30 % 2.77

40 % 1.76

50 % 1.48

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 Daheriya Ritu, Singh V V; International Journal of Advance Research, Ideas and Innovations in Technology

Compressive Strength,
4
3

N/mm2
2
1
0
0% 10% 20% 30% 40% 50%
% of Sludge

Fig. 7 Variation of compressive strength with % of sludge

Above fig. illustrates the compressive strength of the bricks tested. The addition of sludge is in less amount to the other constituents
increased the compressive strength of bricks. Even so, the addition of sludge is more in percentage resulted in a reduction of
compressive strength. However, sludge being finer than soils itself, it also may fill the voids within the soil causing a reduction in
void space thereby making bricks denser. Hence, the filler action of sludge should increase the compressive strength of bricks. The
observed changes in strength should obviously be the sum total of these two effects. Filler action is dominant when percentage
sludge added is less than 5%. Further addition of sludge occupies the space only by pushing the coarse sand particles in the soil
apart. This will result in a reduction in the friction between sand particles which contribute significantly to the compressive strength
of bricks. Therefore, reduction in compressive strength is expected at higher percentages of sludge.

6.2 WATER ABSORPTION TEST OF BRICK

The amount of water absorption is calculated from the following equation.
Amount of water absorbed (%) = (W2-W1)/W1
Where W2 = weight of wet brick in gm,
The W1= weight of dry brick in gm,

Table 3: Results of water absorption test

% of Avg. the weight of dry Avg. the weight of wet Amount of

Sludge bricks(W1) (gm) bricks(W2) (gm) Water Absorbed (%)

0% 2766.33 3256.00 17.70

10 % 2509.67 2965.00 18.14

20 % 2130.33 2559.33 20.14

30 % 1854.67 2246.67 21.14

40 % 1575.00 1931.00 22.60

50 % 1291.00 1612.33 24.89

30
Water Absorption, %

25
20
15
10
5
0
0% 10% 20% 30% 40% 50%
% of sludge

Fig. 8: Water absorption.

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 Daheriya Ritu, Singh V V; International Journal of Advance Research, Ideas and Innovations in Technology
6.3 EFFLORESCENCE TEST
The efflorescence test of the brick is conducted by placing the end of the brick in the dish and the distilled water is filled up to the
depth of 25mm. The whole arrangement is made at the room temperature with the well-ventilated room until all water in the dish is
absorbed by the brick and the surface water evaporate. The dish is covered in order to reduce excess evaporation. When the water
is absorbed the bricks appeared to be dry, place a similar quantity in the dish allows it to evaporate as made before.
Table 4: Results of efflorescence test

% of Sludge Status
0% Nil

10 % Slight

20 % Moderate

30 % Moderate

40 % Heavy

50 % Serious

6.4 SOUNDNESS TEST

In this test, we have checked the bricks to check its hardness in case of the sudden impact. The two bricks are taken and made struck
with each other. Brick of good quality should not break and produce a ringing sound. The ringing sound of brick goes on decreasing
with increase in the amount of sludge content. Ringing sound is excellent for original bricks with 0% sludge. Ringing sound is least
for 20% of sludge addition bricks. This may be because of increased porosity of the bricks. For bricks, up to 20% sludge addition
has good ringing sound is heard.

6.5 HARDNESS TEST

Scratch is made on the brick surface with the help of finger nail. If no impression on the surface, the brick is sufficiently hard. First
three sample shows good results and last three samples does not show good results.

6.6 DIMENSIONS TOLERANCE TEST (IS 1077-1970)

The test is performed to check whether the bricks are of required dimensions or not. The results are as follows
Table 5 Dimensions tolerance test

S. No Trial Dimensions, cm
1 1 395 X 196 X 191
2 2 392 X 195 X 192
3 3 396 X 195 X 192

7. COST ESTIMATION
After all the tests over the dry sludge bricks, we did an analysis to the cost of the bricks. The analysis of the cost of the brick is done
on the basis of the four factors
 Price of clay soil
 Price of sludge
 Price of fly ash
 Labor cost
According to the mix design calculation, we achieved the weight of water, sludge and fly ash for bricks. As the water is largely
available in India, its costs can, therefore, be neglected. The current study shows that replacement of soil using sludge can be made
as much as 20% (by weight). After the Analysis, we come to know that as the percentage of the sludge in the brick is increasing,
the cost of the brick is decreasing in the same way.

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 Daheriya Ritu, Singh V V; International Journal of Advance Research, Ideas and Innovations in Technology
Table 6: Cost analysis of brick

% of Weight of
Cost per Brick, Rs
Sludge bricks (gm)

0% 2766 5.58

10 % 2500 4.52

20 % 2130 4.17

30 % 1850 3.78

40 % 1570 3.45

50 % 1290 3.14

4
Cost, Rs

0
0% 10% 20% 30% 40% 50%
% of Sludge

Fig. 9: Variation of cost analysis of brick with % of sludge

On the basis of the analysis done, it comes to know that the cost of the brick is reducing the use of dry sludge in it. According to the
Government norms, the sludge can be avail at free of cost including transport charges. Hence the cost of the brick is decreasing with
the increase in the quantity of dry sludge in the brick.

8. CONCLUSION
From the study of this work, it has been concluded that dry sludge can be used for the manufacturing of the brick. Hence it is the
good alternate to the disposal of the dry sludge.
 After the testing of all the brick samples for the compressive strength it comes to know that bricks made up of sludge up to
10 percent can be used for the construction of all the structures as it has the satisfactory results in the form of the hardness.
Compressive strength decreases with the replacement of dry Sludge with ordinary soil as compare to traditional Brick.
 All the samples of the sludge bricks were tested for the Water Absorption test and after the study of observations, it comes
to know that the samples have good results. The water absorption increases with the replacement of soil by dry Sludge. A
good correlation between all properties tested was observed.
 Ringing sound is excellent for original bricks with 0% sludge. Ringing sound is least for 20% of sludge addition bricks.
This may be because of increased porosity of the bricks. For bricks, up to 20% sludge addition has good ringing sound is
heard.
 Scratch is made on the brick surface with the help of finger nail. If no impression on the surface, the brick is sufficiently
hard. It shows within the limit.
 The efflorescence test of the brick is conducted by placing the end of the brick in the dish and the distilled water is filled up
to the depth of 25mm.The whole arrangement is made at the room temperature with the well-ventilated room until all water
in the dish is absorbed by the brick and the surface water evaporate. The dish is covered in order to reduce excess
evaporation. When the water is absorbed the bricks appeared to be dry, place a similar quantity in the dish allows it to
evaporate as made before.
 The test is performed to check whether the bricks are of required dimensions or not. It shows within the limit.
 It utilizes waste material such as sludge & fly ash whose management leads to the expenditure of millions of fund by the
Indian government. Hence it is economically feasible.

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 Daheriya Ritu, Singh V V; International Journal of Advance Research, Ideas and Innovations in Technology
 Sludge and Fly ash both pollute the environment in a number of ways. Because fly ash and sludge cause several diseases.
Since our work utilizes the use of both wastes in making of Brick which is non-harmful in nature. Hence it is environmentally
feasible.
 Finally, we recommended with this study sewage-fly ash bricks are not much useful. Because it causes harmful diseases to
the labor.

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